Case 580D Backhoe Loader Service Manual 1981 (P/N 9-69270)

This factory service manual covers the J I Case 580D tractor-loader-backhoe with naturally aspirated and turbocharged 207 diesel engines. P/N 9-69270 dates from January 1981; revised sections carry 9-69271 and 9-69272, with revisions through August 1983. Starter and alternator sections are marked 9-69720.

PDF Search, Bookmarks, and Wiring Detail

Section access and small labels: PDF text search is not available. Embedded bookmarks reach the three-point-hitch control-valve section; later chapters are not bookmarked. Small wiring labels require zooming, and the basic chassis diagram has softer detail than the accompanying wire-color tables.

One printable PDF contains 1,726 pages, including the section covers and revised sheets.

Engine, Powertrain, and Hydraulic Workshop Coverage

The following selected topics outline the repair coverage rather than reproduce the full contents. Other examples include air-cleaner service and ether-starting equipment.

• Engine overhaul: Step-by-step removal, inspection, reassembly, adjustment, and run-in procedures, covering the cylinder head, valve train, camshaft, gear train, cylinder block, wet sleeves, pistons, connecting rods, crankshaft, main bearings, flywheel, and oil seals.

• Fuel, cooling, and lubrication: Roosa Master DB injection equipment, fuel lines, tank and engine controls, turbocharger service, oil-pump repair, and cooling-system work.

• Powertrain and brakes: Power-shuttle pressure testing, torque-converter and clutch service, control linkage, transaxle and differential-lock repair, four-wheel-drive transfer gearbox work, drive shafts, wheels, tires, and self-adjusting brakes.

• Hydraulic components: Pump testing; loader, backhoe, and stabilizer valve disassembly and reassembly; cylinder disassembly, inspection, resealing, bushing replacement, and installation.

• Electrical diagnosis: Wiring diagrams, starting-circuit fault tracing, starter and solenoid tests, alternator checks, battery service, and instrument-cluster and panel repair.

• Steering and front axles: Steering-pump, control-valve, and cylinder repair, leakage and relief-pressure checks, and separate two- and four-wheel-drive front-axle sections.

• Attachments and cab equipment: Loader and backhoe removal and adjustment, three-point-hitch hydraulics, ROPS cab and canopy service, seat service, noise control, and air-conditioning diagnosis.

This manual is suited to service technicians equipped for pressure testing, internal component work, and removal of heavy assemblies.

Build Differences and Component Selection

The 580D specification and overhaul material centers on the 207 diesel. Some diagnosis and tune-up chapters are shared with the 188, while separate transaxle, differential-lock, and brake sections distinguish naturally aspirated and turbocharged machines.

Hydraulic sections identify Parker Hannifin and Hydreco loader valves, standard and Super D backhoe-control layouts, and early and late swing-cylinder circuits. Backhoe installation drawings distinguish machines with or without the optional three-point hitch and bucket-cylinder arrangements for the extendable dipper. Those differences help prevent parts or procedures from being selected for the wrong build.

Engine Diagnosis and Rebuild Support

Symptom charts address hard starting or no-start, misfire, knock, overheating, power loss, excessive oil consumption, and low oil pressure. Tune-up procedures cover top-dead-center location, valve adjustment, injector removal and spray-pattern testing, compression checks, injection-pump timing, governed-speed adjustment, and final checks.

Separate torque-converter and hydraulic stall tests explain how results point toward engine, power-shuttle, or hydraulic faults. Internal inspection data includes wear limits, clearances, fluid capacities, and component-specific tightening references.

The Teflon valve-seal procedure explains how valve-stem grooves can cut a new seal during installation. Turbocharger guidance addresses oil priming after installation or extended storage to prevent bearing damage from inadequate lubrication.

Drivetrain Setup and Hydraulic Fault Isolation

Power-shuttle chapters cover control-valve, charging-pump, and clutch work, with pressure-gauge tests and result interpretation. Transaxle repair extends to gears, shafts, differential bearing preload, and ring-and-pinion backlash; four-wheel-drive front-axle work includes planetary hubs, swivel housings, axle shafts, and differential setup.

Brake chapters include master-cylinder rebuilding, pedal adjustment, hydraulic bleeding, and parking-brake control service.

Hydraulic diagnosis separates loader, backhoe, and steering output and leakage tests. Relief-valve checks, steering relief and unloading valves, quick-disconnect couplings, boom-lock operation, contamination diagnosis, and portable filtration are covered alongside component repair.

Loader and Backhoe Service

Loader adjustments include return-to-dig and antirollback settings. Backhoe work covers swing-tower pivot bushings, bearing washers, and replacement of wear strips for the dipper extension.

Electrical, Air-Conditioning, and Diagram References

Starting-circuit diagnosis includes harness continuity and voltage-loss tests. Charging checks distinguish wiring, voltage-regulator, and internal alternator faults.

Factory illustrations include the engine diagnosis chart, standard-canopy and cab/air-conditioner wiring diagrams, the basic chassis wiring diagram, loader-backhoe steering circuits, four-wheel-drive front-axle exploded views, power-shuttle and torque-converter assembly views, and loader/backhoe valve oil-flow sections.

Air-conditioning charts distinguish no cooling, insufficient cooling, erratic cooling, and system noise. Pressure/temperature checks support service of the compressor, clutch, shaft seal, valve plate, expansion valve, evaporator, condenser, receiver-drier, and ROPS-cab lines.

Special-tool references include the CAS-1153 flex-plate alignment tool, M20624 valve-seal installer, M20615 valve-guide cutter, A43278 injector removal tool, A43277 injector-bore cleaner, and CAS-1617 turbocharger seal tool.

Cylinder Sleeve and Piston Fit Preview

For the naturally aspirated 207 diesel, the detailed specifications list a cylinder-sleeve inside diameter of 4.000–4.0010 inches, with a maximum serviceable limit of 4.0020 inches.

Sleeve-to-piston-skirt clearance is 0.0040–0.0060 inch, measured at the bottom of the skirt, 90° to the piston pin. The maximum serviceable clearance is 0.0080 inch.

Raised loader and backhoe structures, stored hydraulic pressure, heavy powertrain assemblies, rotating engine parts, and refrigerant require correct blocking, pressure release, lifting equipment, and system isolation. Use the complete factory section and its safety notes before beginning any repair or adjustment.